Original Doohickey failed - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
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post #1 of 3 Old 07-24-2016, 10:32 AM Thread Starter
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Join Date: Jul 2016
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Original Doohickey failed

Just bought an '04 KLR with 16k miles. The previous owner (who was the second owner) never heard of a Doohickey, so the first thing I did was replace it. Got the whole kit with tools from Eagle Mike.

Took me all afternoon to replace it because I'm a rookie. Anyway, when I removed the factory part it was partially broken. Half the collar around the top of the bolt hole was missing. Of course I looked all over inside with a flashlight, including the rotor magnet, the pieces I removed, and the old oil. Never found a trace of that missing piece.

Now my question is what do I do? Beyond making a reasonable attempt to find the broken piece there's nothing I can do but hope for the best and keep riding. My next purchase is a magnetic drain plug. Thoughts?
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post #2 of 3 Old 07-25-2016, 02:09 AM
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Join Date: Jul 2016
Location: East GTA
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Stick an extension magnet into the sump from the left cover area?

When I did my doohickey last week, I found a random flathead screwdriver bit (could've been on the rotor magnet, all I know is at some point an oily bit fell out of the engine). Something tells me that while the metal chunk can be bad news, the lack of tensioning is probably the worse side of it all, as it can cause chains to jump and apparently mess up cam timing/chain.
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post #3 of 3 Old 07-25-2016, 06:32 PM
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Join Date: May 2014
Location: Texas
Posts: 1,261
Everyone seems to eventually find all the broken pieces by fishing with a good magnet on a very flexible stem.

Remove the idler sprocket that the doohickey controls and fish through the hole behind it. If all else fails pull the clutch cover on the right and fish through the oil strainer screen hole.
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